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Discussion Starter #1
Well after several hours, I still don't have the OEM grips on. I have the electrical - i have the grips on -except no matter what i do i have a cruise control on the right grip. when i tighten up the holder, the throttle twist open and stays there. it won't return. It returns before I tighten
I've taken it apart, re-attached the cables & the little cylkiners - I have tried adjusting the cable adjusters - i have tried twisting it this way and that - something is bound up - any ideas please. thanks
Also anyone know what the large black washer is for? there in nothing in the instructions about it
 

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FORUM GODFATHER.....R.I.P. PAT
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Which cruise control? Does it bind with the cruise control removed, with the bar weight removed, with both removed? You need to find where it's binding.
 

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Discussion Starter #3 (Edited)
Sorry - I meant it acts like an unintended cruise control - you open the throttle and it stays there. I do not have a cruise control installed. Whatever spring force returns the throttle normally to idle, cannot overcome the friction when i tighten the case screws. I can twist it back to idle, and it works fine right up until i snug up the screws. It's like the new grip is larger diameter or thicker or something. I was looking this morning at the two throttle grips, and the heated grip has a larger plastic collar than the stock one where it fits into the case. I did lube it, but i think I may have to remove some material in the new grip to slightly reduce the diameter. But I have not heard of anyone having to do this and I don't like putting my new $$$ grips under the grinder.
 

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FORUM GODFATHER.....R.I.P. PAT
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It's not the diameter. It's probably rubbing the switch housing or the bar end weight. Check the switch housing to grip clearance. You should see a space there. The check the other end, take the weight off the bar end. To do that, back the screw out of the end no more than 3/4" then push the screw in and wiggle the whole assembly out.
 

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Discussion Starter #5
Thanks. It's not the bar end weight 'cause I'm not refitting that until the throttle works properly. As soon as that happens I'm finishing it off with the handguards. So, I'll fudge around with it some more.
 

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Maybe it's how the holder/clamp thing is lining up with the channel that the cables hook in to?

I'm kinda anxious to hear how this gets resolved because I have my old grips off and the OEM grips ready to put on as soon as I get the time (maybe Sunday? sheesh!).

When I took my stock grips off, I was fairly amazed to find that the throttle side is just a rubber-covered plastic tube that slides around the handlebar; there doesn't seem to be much that can get stuck or bind.

- Martin
 

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FORUM GODFATHER.....R.I.P. PAT
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The grip rubbing the switch housing is a typical problem.
 

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Discussion Starter #8
No, it's not the throttle tube binding on the handlebar. It's something to do with how the two clamshell halves of the throttle case come together, and the way the collar on the grip is fitting in there. Or it's the cables binding. It's like this - if I assemble everything on the bar and hold the clamshell halves together, it works as before. When I put the screws in and tighten them, it's clamping down on the throttle tube somewhere. I can't look at right now. It says 2 hours on the instructions. Ha. Not for me :rolleyes:
 

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FORUM GODFATHER.....R.I.P. PAT
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Can you see a space between the grip and the switch housing? Did you separate the housing as part of the installation? there was no need to. Something could have gotten in there if you did.
 

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Discussion Starter #10
Yes i did separate them. maybe something fell out? or in? Or something is not where it's supposed to be in there. I'll check it out. thanks.
 

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Discussion Starter #11 (Edited)
OK here's a picture. As you can see the new grip on the right is larger, and differently shaped. here is also the part #.

57100-06870

Does this jive with what you guys have installed?
 

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Discussion Starter #12
As you can see i am tempted to just grind off the excess.
 

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FORUM GODFATHER.....R.I.P. PAT
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Aha! I had no idea the OEM heated grips came with a new throttle tube. That's why the aren't a listed accessory for the '07 DL650. The switch housing and throttle pulley changed for '07. http://www.suzukionly.com/eshopprod_cat_3114-4167-26724-10716_product_354305.Heated_Grip_Set.htm mentioned it's not for the '07 650. Either return them if you can or, if you feel comfortable with altering them, do that. I apologize for my poor assumption that the new grips slid over the old throttle tube.
 

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Discussion Starter #14 (Edited)
I finally got the heated grips & handguards on. I had to make the simple alteration of grinding off part of the throttle tube collar/cable attachment do-hickie that you can see in the previous pic. Since it was just slightly binding as it came out-of-the-box, it didn't need much - very simple to do on a bench grinder. I cleaned up the stringy junk left from the grinder with a blade edge & a small wire brush.
After I got it assembled for the umpteenth time, there was some slop in the longitudinal direction (not rotational) on the tube, about 1/8". :idea: How about that big black washer with the hole about the size of the handlebars that was in the box but was not mentioned or shown in the instructions? :mrgreen: Yep. It fit perfectly between the inside grip edge and the side of the switch housing. So I took it apart for what I hope is the last time in the near future, put in the washer, and it works great. I put a bit of grease on it - it also serves as a seal between the tube & housing. It removed all but the slightest slop.
They heat up quickly and evenly on left & right. I put the hot side up on the left. No choice on the right.
Handguards went on easily. The throttle cables have to point up a bit, but they are still straight - no danger of kinks. I did not see the need for grinding the RH "knuckle cover".
Now, I just need to route the heater cables, cable-tie them up and button the body parts back on. Fingers crossed. :rolleyes: Then, I'm goin' ridin'!
 
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